Devices, systems, facilities and processes for carbon capture optimization in industrial facilities

ABSTRACT

Devices, systems, and methods for carbon capture optimization in industrial facilities are disclosed herein. An example carbon capture process involves cooling a flue gas stream using at least one gas-to-air heat exchanger disposed upstream of a carbon dioxide (CO2) absorber. Another example carbon capture process involves heating a heat medium for solvent regeneration and CO2 stripping using a fired heater and/or using at least one waste heat recovery unit.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. Pat. Application No.17/861,142, filed Jul. 8, 2022, entitled DEVICES, SYSTEMS, FACILITIESAND PROCESSES FOR CARBON CAPTURE OPTIMIZATION IN INDUSTRIAL FACILITIES,which is a divisional of U.S. Pat. Application No. 17/556,332, filedDec. 20, 2021, entitled DEVICES, SYSTEMS, FACILITIES AND PROCESSES FORCARBON CAPTURE OPTIMIZATION IN INDUSTRIAL FACILITIES, the entirecontents of which is incorporated by reference herein and relied upon.

BACKGROUND

Industrial facilities that utilize combustion fuels may generategreenhouse gases. Greenhouse gases include various gaseous compounds,such as carbon dioxide, methane, nitrous oxide, hydrofluorocarbons,perfluorocarbons, and sulfur hexafluoride for example, which absorbradiation, trap heat in the atmosphere, and/or otherwise contribute toundesirable environmental greenhouse effects.

Carbon capture processes can be employed to remove and/or reducegreenhouse gas emissions. There are several challenges associated withtraditional implementations of post combustion carbon capture processesin industrial facilities. One challenge involves parasitic power loadswhich may negatively impact the output and efficiency of an industrialfacility that employs the carbon capture process. Another challengeinvolves additional cooling water loads traditionally used in carboncapture systems and the environmental impacts related to the use of suchadditional cooling water. To enable effective absorption of carbondioxide from a flue gas and reduce degradation of the absorbing media,conventional carbon capture processes typically use evaporative coolingwater systems to cool the carbon dioxide rich flue gas. Cooling watersystems can be costly as they typically require a stream of make-upfresh water to replenish their cooling water loop, and thus place asignificant demand on utilities and fresh-water sources.

SUMMARY

The present disclosure provides novel and improved carbon capturesystems, devices, facilities, and methods. In an example, a method forprocessing a flue gas stream involves cooling the flue gas stream usingat least a gas-to-air heat exchanger disposed upstream of and in fluidcommunication with a carbon dioxide (CO2) absorber. The method alsoinvolves moving, by a flue gas blower, the flue gas stream through thegas-to-air heat exchanger and the CO2 absorber. The method also involvesmoving, by a cooling air blower, air through the gas-to-air heatexchanger to cool the flue-gas stream.

In an example, a method for processing a flue gas stream involvesreceiving, at a solvent regenerator, a rich solvent flowing from acarbon dioxide (CO2) absorber. The rich solvent includes CO2 capturedfrom the flue gas stream in the CO2 absorber. The method also involvesheating a heat medium using at least a fired heater. The method alsoinvolves transporting the heated heat medium from the fired heater tothe solvent regenerator. The method also involves generating a firedheater flue gas by the fired heater. The method also involvestransporting the fired heater flue gas into the flue gas stream at aposition upstream of the CO2 absorber.

In an example, a system for processing a flue gas stream includes agas-to-air heat exchanger disposed upstream of and in fluidcommunication with a carbon dioxide (CO2) absorber. The gas-to-air heatexchanger to receive and cool the flue gas stream. The gas-to-air heatexchanger to transport the cooled flue gas stream through and out of thegas-to-air heat exchanger toward the CO2 absorber. The system alsoincludes a flue gas blower to move the flue gas stream through thegas-to-heat exchanger and the CO2 absorber. The system also includes acooling air blower to move air through the gas-to-air heat exchanger tocool the flue gas stream.

In an example, a system for processing a flue gas stream includes acarbon dioxide (CO2) absorber to receive the flue gas stream. The systemalso includes a solvent regenerator in fluid communication with the CO2absorber. The solvent regenerator to receive a rich solvent from the CO2absorber and to provide a lean solvent to the CO2 absorber. The leansolvent having a lower amount of CO2 than the rich solvent. They systemalso includes a fired heater in fluid communication with the solventgenerator. The fired heater to heat and transport a heat medium towardthe solvent regenerator. The fired heater to generate a fired heaterflue gas and transport the fired heater flue gas out of the fired heaterfor combination with the flue gas stream at a position upstream of theCO2 absorber.

Additional examples, features, and advantages of the disclosed devices,systems, facilities, and methods are described in, and will be apparentfrom, the following Detailed Description and the Figures. The featuresand advantages described herein are not all-inclusive and, inparticular, many additional features and advantages will be apparent toone of ordinary skill in the art in view of the figures and description.Also, a particular embodiment does not necessarily have all of theadvantages listed herein. Moreover, it should be noted that the languageused in the specification has been principally selected for readabilityand instructional purposes, and not to limit the scope of the inventivesubject matter.

BRIEF DESCRIPTION OF THE FIGURES

Understanding that the figures depict specific example embodiments andare not to be considered to be limiting the scope of the presentdisclosure, the present disclosure is described and explained withadditional specificity and detail through the use of the accompanyingfigures. The figures are listed below.

FIG. 1 is a schematic illustration of an example carbon capture facilitythat includes a cooling arrangement and a heating arrangement, accordingto an example embodiment.

FIG. 2 is a schematic illustration of a first example coolingarrangement that includes a gas-to-air heat exchanger for cooling a fluegas stream in a carbon capture process, according to an exampleembodiment.

FIG. 3 is a schematic illustration of a second example coolingarrangement that includes multiple gas-to-air heat exchangers forcooling a flue gas stream in a carbon capture process, according to anexample embodiment.

FIG. 4 is a schematic illustration of a first example heatingarrangement that includes a waste heat recovery unit, according to anexample embodiment.

FIG. 5 is a schematic illustration of a second example heatingarrangement that includes multiple waste heat recovery units, accordingto an example embodiment.

FIG. 6 is a schematic illustration of a third example heatingarrangement that includes a driver for generating power and driving aCO2 compressor, according to an example embodiment.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

Although the following text sets forth a detailed description ofnumerous different embodiments, it should be understood that the legalscope of the invention is defined by the words of the claims set forthat the end of this patent. The detailed description is to be construedas exemplary only and does not describe every possible embodiment, asdescribing every possible embodiment would be impractical, if notimpossible. One of ordinary skill in the art could implement numerousalternate embodiments, which would still fall within the scope of theclaims. Unless a term is expressly defined herein using the sentence “Asused herein, the term ‘__’ is hereby defined to mean...” or a similarsentence, there is no intent to limit the meaning of that term beyondits plain or ordinary meaning. To the extent that any term is referredto in this patent in a manner consistent with a single meaning, that isdone for sake of clarity only, and it is not intended that such claimterm be limited to that single meaning. Finally, unless a claim elementis defined by reciting the word “means” and a function without therecital of any structure, it is not intended that the scope of any claimelement be interpreted based on the application of 35 U.S.C. § 112(f).

The present disclosure provides novel processes, apparatuses, andsystems that can be used individually or in combination to optimizeutility costs associated with a carbon capture process, such as costsassociated with cooling a post-combustion flue gas stream and costsassociated with heating a heat medium for a solvent regeneration and CO2stripping process.

Referring now to the figures, FIG. 1 illustrates an exemplary schematicof a carbon capture facility 100. The facility 100 receives apost-combustion flue gas stream 10, which may be from an industrialfacility or other combustion system. The flue gas stream 10 istransported through one or more components of the system 100 along afluid path defined by fluid connections or conduits 102-108. Thedirections of each of the arrows 102-108 in the illustration of FIG. 1represents a downstream direction of the flow path of the flue gasstream 10 from or to component(s) of the system 100 at end(s) of therespective arrow.

For example, the conduit 102 transports the flue gas stream 10downstream to a cooling arrangement 110. The cooling arrangement 110 isdisposed upstream of absorber 120 to cool the flue gas stream 10 flowingout of the cooling arrangement toward and into the absorber 120 viaconduit 106. The flue gas stream 10 then flows out of the absorber 120at conduit 108 as a waste gas stream having a lower concentration of CO2than the flue gas stream 10 flowing into the absorber 120. In anexample, the waste gas stream 10 exiting the absorber 120 via theconduit 108 may be released into the atmosphere. A bypass conduit 104may be included to enable selectively routing the flue gas stream 10 (ora portion thereof) out of the conduit 102 and away from other componentsof the carbon capture facility 100 (e.g., away from the coolingarrangement 110, etc.), and thus selectively bypass the carbon captureprocess.

More generally, unless otherwise specified herein, arrows (e.g., arrows102-108, 112-118, 122-128, etc.) depicted in the Figures of the presentdisclosure which extend from or to various components may represent afluid connection or conduit (e.g., piping, etc.) configured to transporta fluid (e.g., flue gas, air, solvent, water, etc.) from or tocomponent(s) at end(s) of the respective arrow. Further, an arrowdirection of the respective arrow represents a flow direction (e.g.,downstream direction) of a fluid flowing inside the conduit representedby the respective arrow.

The absorber 120 may include a contactor (e.g., gas-liquid contactor,gas-to-gas contactor, etc.) or any other type of device in which a leanabsorbing media is brought into contact with the flue gas stream 10flowing inside the absorber 120 to capture CO2 from the flue gas stream10. The absorbing media can be ammonia, amine based, carbonate based(e.g., potassium carbonate), ionic fluid, and/or any other type ofsolvent. Prior to contact with the flue gas stream 10, the solvent(e.g., “lean solvent”) entering the absorber 120 (via conduit 112) isCO2 lean. After contact with the flue gas stream 10, the solvent (e.g.,“rich solvent”) exiting the absorber 120 (via conduit 114) is CO2 rich.In examples, the rich solvent exiting the absorber 120 (via the conduit114) may include a greater amount of CO2 (and/or a greater amount ofcarbon) than the lean solvent entering the absorber 120 (via the conduit112).

A solvent regeneration and CO2 stripping unit 130 may be disposed influid communication with the absorber 120 to receive the rich solvent(via the conduit 114) from the absorber 120 and to provide the leansolvent (via the conduit 112) to the absorber 120. To that end, theregeneration and CO2 stripping unit 130 may be interchangeably referredto herein as a solvent regenerator 130, a regenerator 130, CO2 stripper130, and/or a stripper 130. The regenerator / stripper 130 may beconfigured to convert the rich solvent into the lean solvent bystripping CO2 (or carbon) from the rich solvent. To facilitate this, inan example, the regenerator 130 may heat the rich solvent using a heatmedium (e.g., steam or oil) so as to remove or separate the CO2 (orcarbon) from the rich solvent.

The system 100 may also include a heating arrangement 140 configured toheat the heat medium and provide the heated heat medium to theregenerator 130 via a conduit 116. In examples, the heating arrangement140 may include one or more combustion-based devices configured to heatthe heat medium and thus produce a heating system flue gas. In anexample, the heating system flue gas may be transported out of theheating arrangement 140 (e.g., via a conduit 118) for combination withthe flue gas stream 10 at a front end (e.g., into the conduit 102) ofthe carbon capture system 100 or at any other position upstream of theCO2 absorber 120

The regenerator / stripper 130 may output a CO2 rich stream thatincludes CO2 extracted from the rich solvent to a conduit 122 so as totransport the CO2 rich stream to a compressor 150. The compressor 150may compress the CO2 rich gas stream (received via the conduit 122 fromthe regenerator 130) for other users or applications, such as forsequestration (e.g., underground or underwater storage, etc.) or otherindustrial uses. In some examples, the compressor 150 is a multi-stagecompressor.

The system 100 also includes a driver 160 coupled to the compressor 150.The driver 150 may be configured to provide mechanical energy to thecompressor 150 for compressing the CO2 rich stream (e.g., received atthe compressor 150 from the conduit 122). In examples, the driver 160may be an internal combustion engine or other type of combustion-baseddriver that burns a fuel to produce the mechanical energy for drivingthe compressor 150. As such, in some examples, the compressor driver 160may produce a driver flue gas (e.g., as a byproduct of fuel combustionby the driver 160, etc.). The driver flue gas may be transported out ofthe driver 160 (via a conduit 124) to the heating arrangement 140. Forexample, the heating arrangement 140 may include a waste heat recoveryunit (not shown in FIG. 1 ) configured to extract heat from the driverflue gas to heat the head medium provided (via the conduit 116) to theregeneration and stripping unit 130. Furthermore, in an example, thedriver flue gas may eventually (e.g., after heat recovery in the heatingarrangement 140) be routed (e.g., via the conduit 118) to the front-endof the carbon capture process (e.g., upstream of the cooling arrangement110) or to any other position upstream of the CO2 absorber 120 forcombination into the flue gas stream 10.

The system 100 may also include a CO2 dehydration and post-processingunit 170 in fluid communication with the compressor 150 to receive thecompressed CO2 from the compressor 150 via conduit 126. The dehydrationand post-processing unit 170 may be configured to remove water and/orother constituents (e.g., contaminants, etc.) such that the compressedCO2 is of a suitable quality and composition for an end user of thecompressed CO2. In the illustrated example, the post-processed and/ordehydrated compressed CO2 is transported out of the carbon capturesystem 100 via a conduit 128.

In examples, the compressor 150 and/or the dehydration andpost-processing unit 170 sends (e.g., via the conduit 128 or via anotherconduit not shown in FIG. 1 ) the compressed CO2 away from the system100 to a carbon user or to a sequestration site. In an example, thecompressed CO2 may be sent to an off-site sequestration facility (notshown), such as an underground geological formation that includes an atleast partially depleted hydrocarbon reservoir, or any othersequestration site. In an example, the sequestration site may be on topof a seabed (e.g., at a three kilometer depth or greater below sealevel, etc.). In an example, the sequestration site is below a seabed.

As noted above, conventional carbon capture processes typically coolflue gas using a cooling water quench system with cooling towers (e.g.,“evaporative cooling water system”), which cools the flue gas throughthe evaporation of at least a portion of the cooling water. Suchevaporative cooling water systems typically consume water from anenvironmental source to replenish the evaporated water, and may thushave negative effects on the environment. Furthermore, in somefacilities, it may not be feasible to continuously supply / replenishcooling water for an evaporative cooling water system due to facilitylocation and/or other factors.

Accordingly, example cooling arrangements are disclosed herein, such asthose described below in connection with FIGS. 2 and 3 , thatadvantageously enable cooling a flue gas stream without necessarilyrequiring the use of additional cooling water and/or without necessarilyusing an evaporative cooling water system. To facilitate this, anexample cooling arrangement may include one or more gas-to-air heatexchangers arranged to cool the flue gas stream 10 upstream of the CO2absorber 120.

FIG. 2 is a schematic illustration of an example cooling arrangement200, which may be used to implement the cooling arrangement 110 of thesystem 100 for example.

In the illustrated example, the cooling system 200 includes a gas-to-airheat exchanger 210 disposed upstream of and in fluid communication withthe absorber 120. In examples, the gas-to-air heat exchanger 210 may bea gas-to-gas heat exchanger that uses air as a cooling medium flowingthrough the heat exchanger 210. For example, the heat exchanger 210 maydefine separate flow paths for the air (entering the heat exchanger 210at conduit 206 and exiting the heat exchanger at conduit 208) and theflue gas stream (entering the heat exchanger at conduit 202 and exitingthe heat exchanger at conduit 204) so that the two gas streams (i.e, thecooling air and the flue gas stream) are not mixed with one anotherinside the heat exchanger 210. In an example, the flue gas stream 10 mayflow into the heat exchanger 210 through a first gas inlet (connected toconduit 202) of the heat exchanger 210 and may flow out of the heatexchanger through a first gas outlet (connected to conduit 204). Insidethe heat exchanger 210, heat from the flue gas stream 10 may betransferred to cooling air (e.g., ambient air) or other cooling mediumflowing into the heat exchanger 210 through a second gas inlet(connected to conduit 206) and flowing out of the heat exchanger 210through a second gas outlet (connected to conduit 208).

The system 200 may also include at least one cooling air blower to movethe air flowing through the gas-to-air heat exchanger 210, and at leastone flue gas blower to move the flue gas stream flowing through thegas-to-air heat exchanger 210 and the CO2 absorber 120. In general, ablower is a device (e.g., fan, etc.) structured to vent or move a gas(e.g., flue gas or air) through, toward, and/or away from one or morecomponents, and/or more generally to move the gas along a fluid pathdefined by a system such as the system 200.

Although FIG. 2 depicts two air blowers 212A-B in fluid communicationwith the heat exchanger 210, in some examples, the system 200 mayalternatively include only one of the air blowers 212A-B. For example,the system 200 may be alternatively implemented using a single coolingair blower disposed at one of the positions 212A (upstream) or 212B(downstream) in fluid communication with the heat exchanger 210. Each ofthe positions 212A (upstream) and 212B (downstream) may providedifferent advantages, as described in more detail below.

In an example, the system 200 may include the cooling air blower 212Adisposed upstream of the gas-to-air heat exchanger 210 to blow air(e.g., ambient air) toward the gas-to-air heat exchanger 210. In thisupstream configuration, the air blower 212A may advantageously operateat an increased efficiency due to a relatively cooler temperature of theair flowing through the blower 212A (i.e., prior to being heated insidethe heat exchanger 210). The upstream configuration of the air blower212A may also be associated with lower maintenance costs compared to aconfiguration (e.g., downstream) in which an air blower blows a hotterstream of air. On the other hand, the upstream air blower 212A maycompress (and thus heat) air entering the heat exchanger 210, therebypotentially reducing an efficiency of the heat exchanger 210 withrespect to transferring heat from the flue gas stream 10 to the air ascompared to a configuration where the air flowing into the heatexchanger 210 is relatively cooler.

In an example, the system 200 may include the cooling air blower 212Bdisposed downstream of the gas-to-air heat exchanger 210 to blow the air(i.e., after the air exits from the heat exchanger 210 via conduit 208)away from the gas-to-air heat exchanger 210. With such downstreamconfiguration, the blower 212B may advantageously improve a coolingefficiency of the heat exchanger 210 by pulling the air exiting from theexchanger 210 (via conduit 208) instead of pushing the air flowing intothe exchanger 210 (via conduit 206). In particular, the downstreamposition 212B of the air blower may result in relatively cooler airentering the exchanger 210, because the air is not compressed (and thusheated) by the downstream air blower 212B until after it exits the heatexchanger 210 (via conduit 208). On the other hand, the downstreamposition of the air blower 212B may be associated with increased powerrequirements and/or maintenance costs due to relatively warmer airflowing through the blower 212B after it exits the heat exchanger 210(as compared to power requirements / maintenance costs associated withblowing cooler air).

Thus, in some examples, a carbon capture process (e.g., system 100) thatimplements the cooling system 200 can be optimized by selecting asuitable position 212A (upstream) or 212B (downstream) for positioningthe cooling air blower, depending on system parameters such as coolingefficiency requirements, parasitic load requirements, maintenance costrequirements, temperature range of the flue gas stream 10, flow rate ofthe flue gas stream 10, and/or any other parameters or tolerancesspecific to an industrial facility or carbon capture process thatemploys the cooling arrangement 200.

In some examples, the heat exchanger 210 may use a different type of gasas a cooling medium instead of or in addition to air. In an example, thewaste gas stream exiting from the absorber 120 (or a portion thereof)can optionally be used to cool the relatively hotter CO2 flue gas streaminside the heat exchanger 210 in addition to or instead of ambient air.More generally, in some examples, the system 200 may advantageouslyenable using a gas (e.g., cooling air) as a cooling medium for coolingthe flue gas stream 10. For example, unlike evaporative cooling watersystems which rely on water evaporation and which replenish theevaporated water using an external water source (e.g., lake, river,etc.), the system 200 may enable cooling a flue gas stream by usingambient air and/or any another cooling gas medium readily available tothe system 200.

The system 200 also includes at least one flue gas blower 214A-C to movethe flue gas stream through the heat exchanger 210 and the absorber 120.Although FIG. 2 depicts three flue gas blowers 214A-C in fluidcommunication with the heat exchanger 210, the system 200 mayalternatively include fewer or more flue gas blowers. In some examples,the system 200 is implemented using a flue gas blower disposed at one ofthe positions 214A-C without one or more of the other flue gas blowers.In an example, one of the positions 214A-C may be selected as a positionof a flue gas blower coupled to the heat exchanger 210 depending onvarious applications of the system 200. As described in more detailbelow, each of the positions 214A-C may have different advantages whichmay be suitable for various different applications of the system 200.

In an example, the system 200 may include the flue gas blower 214Adisposed upstream of the heat exchanger 210 to blow the flue gas stream10 toward the heat exchanger 210. A flue gas blower at the position 214Amay advantageously add energy to the flue gas stream 10 (in the form ofheat due to compression by the blower 214A) prior to entry of the fluegas stream 10 into the heat exchanger 210. For example, the energy (or aportion thereof) added by the upstream blower 214A could potentially beremoved or reduced by the heat exchanger 210. However, a flue gas blowerdisposed at the position 214A may receive the flue gas stream 10 havinga relatively higher temperature, and could thus potentially require morepower to operate than if it were blowing relatively cooler flue gas.Further, the blower 214A may need to be constructed using relativelymore expensive materials that can withstand the elevated temperaturesand/or may require more frequent maintenance actions compared to aconfiguration where a blower blows relatively cooler flue gas.

In an example, the system 200 may include the flue gas blower 214Bdisposed downstream of the gas-to-air heat exchanger 210 (and upstreamof the absorber 120) to blow the flue gas stream 10 (after it is cooledby the heat exchanger 210) away from the heat exchanger 210. A flue gasblower at position 214B may advantageously contact the flue gas stream10 after it is cooled by the heat exchanger 210. Due to the relativelylower temperature of the flue gas stream at position 214B, the flue gasblower 214B may be associated with relatively lower power requirements,material costs, and/or maintenance costs compared to a flue gas blowerat position 214A. On the other hand, positioning the flue gas blower atposition 214B may result in adding energy (i.e., heat due to compressionby the flue gas blower 214B) into the flue gas stream 10 after it iscooled by the heat exchanger 210, thereby warming up the flue gas streamentering into the absorber 120, and thus potentially reducing a carboncapture efficiency of a solvent in the absorber 120. For instance, thesolvent may capture CO2 more efficiently at lower temperatures.

In an example, the system 200 may include the flue gas blower 214Cdisposed downstream of the absorber 120 to blow the waste gas streamaway from the absorber 120. As noted above, the waste gas streamincludes at least a portion of the flue gas stream 10 exiting theabsorber 120 (after CO2 is absorbed by a solvent in the absorber 120),and thus the waste gas stream has a lower concentration of CO2 than theflue gas stream 10 entering the absorber 120. As such, a flue gas blowerdisposed at the position 214C may advantageously blow the waste gasstream having a lower volume and lower temperature than the flue gasstream 10 at positions 214A-B, which may result in efficiencyimprovements and/or power load reductions compared to blowing highervolumes of flue gas at higher temperatures. However, disposing the fluegas blower at position 214C may be associated with higher installationand/or maintenance costs in some scenarios. For example, in someconfigurations, the waste gas stream may be output from a top side ofthe absorber 120, and thus using the position 214C may requireinstalling the flue gas blower at a relatively higher elevationassociated with relatively more challenging structural requirements tosupport the flue gas blower 214C effectively and safely at the higherelevation.

As noted above, the system 200 can be optimized by customizing thenumbers and/or positions of the cooling air blower and/or the flue gasblower depending on the specific parameters and tolerances of the carboncapture process that employs the cooling system 200 (e.g., temperatureof flue gas stream, flow rate of the flue gas stream, parasitic loadthreshold, cost requirements, etc.). For example, position 214A may bemore desirable in some industrial facility applications than position214C, or vice versa.

The system 200 may also include a closed loop water filtration unit 220in fluid communication with the heat exchanger 210. For example, theclosed loop water filtration unit 220 may be coupled to a ducting of thegas-to-air heat exchanger 210 so as to provide water (via conduit 212)which is sprayed onto the flue gas stream 10 inside the heat exchanger210 to separate particulates. The condensed water including theimpurities (e.g., contaminants such as sulfur oxides, etc.) removed fromthe flue gas stream 10 may then be collected and returned to the closedloop water filtration unit 220 (via conduit 214), where the water isfiltered to remove the contaminants and returned to the heat exchanger210 to complete the closed water filtration loop. With this arrangementfor instance, an efficiency of the solvent in the absorber 120 couldpotentially be improved by removing these contaminants upstream of theabsorber 120. Alternatively or additionally, although not shown, theclosed loop water filtration unit 220 may be coupled to the absorber 120to cool and/or wash the waste gas stream exiting from the absorber 120.

FIG. 3 is a schematic illustration of another example coolingarrangement 300 that includes multiple gas-to-air heat exchangers 210,310 disposed upstream of the absorber 120, in accordance with thepresent disclosure. In some scenarios, a single gas-to-air heatexchanger may be insufficient to cool the flue gas stream 10 to asuitable temperature for efficient absorption of CO2 by the solventinside the absorber 120. As such, in the illustrated example, one ormore additional gas-to-air heat exchangers (e.g., heat exchanger 310)may be disposed upstream of the absorber 120 to further cool the fluegas stream 10 prior to flowing into the absorber 120.

In the example of FIG. 3 , the gas-to-air heat exchanger 310 may receive(via conduit 102) and cool the flue gas stream 10 and then thegas-to-air heat exchanger 210 may receive the cooled flue gas stream 10to further cool the flue gas stream 10 prior to the flue gas stream 10flowing into the absorber 120.

To that end, in the illustrated example, the cooling system 300 mayinclude the flue gas blower 214A, 214B, and/or 214C to move the flue gasstream 10 through the heat exchanger 310, the heat exchanger 210, andthe absorber 120. In an example, although not shown, the system 300 mayinclude a flue gas blower disposed upstream of the heat exchanger 310instead of or in addition to the flue gas blowers 214A, 214B, and/or214C.

Further, the system 300 may include a cooling air blower 312A disposedupstream of the heat exchanger 310 to blow cooling air toward andthrough the heat exchanger 310 (e.g., similarly to the blower 212A ofheat exchanger 210), and/or include a cooling air blower 312B disposeddownstream of the heat exchanger 310 (e.g., similarly to blower 212B ofheat exchanger 210) to blow and move the cooling air away and throughthe heat exchanger 310.

More generally, the cooling systems 110, 200, 300, etc., of the presentdisclosure may be customized according to the needs of an industrialfacility that employs the carbon capture process 100. Thus, the numbersand/or positions of the gas-to-air heat exchangers, cooling airblower(s), and/or flue gas stream blower(s) used in the system 200and/or 300 can be customized depending on factors such as the flow rateof the input flue gas stream 10, the temperature of the input flue gasstream 10, power availability for the carbon capture process, amongother factors specific to the industrial facility that employs thesystems and processes of the present disclosure.

In line with the discussion above, the example cooling systems 200, 300,etc., of the present disclosure may advantageously solve challengesassociated with implementing a carbon capture process by enabling thecooling of a flue gas stream without necessarily using an evaporativecooling water system that requires a stream of make-up water.

As mentioned earlier, adopting carbon capture processes in someindustrial facilities may also be challenging due to heat loadrequirements for solvent regeneration and/or CO2 stripping processes andpower load requirements associated with operating a carbon capturefacility (e.g., for operating blowers, etc.), which may sometimesrequire major upgrades to the existing infrastructure of an industrialfacility. Accordingly, FIGS. 4-6 illustrate example optimized heatingand power generation arrangements that can be used to optimize a carboncapture process and/or solve these challenges.

FIG. 4 is a schematic illustration of an example carbon capture system400 that includes an example heating arrangement for solventregeneration and CO2 stripping, according to the present disclosure.System 400 depicts an example embodiment of the system 100, where theheating arrangement 140 of the system 100 includes a fired heater 410, awaste heat recovery unit 420, and a power generator 430.

The fired heater 410 (e.g., industrial furnace) is heater that burns acombustion fuel and transfers heat from the combustion gases to a heatmedium that is transported out of the fired heater to the regenerator130 via the conduit 116. As noted above, the heat medium may include anysuitable heat medium such as steam or oil. The regenerator or stripper130 uses the heated heat medium to regenerate the CO2 rich solventreceived from the absorber 120 into a lean solvent by stripping the CO2from the rich solvent.

As a by-product of the combustion process in the fired heater 410, thefired heater 410 may produce a heater flue gas. In the illustratedexample, the heater flue gas is transported (via a conduit 406) out ofthe fired heater 410 and combined with the flue gas stream 10 upstreamof the absorber 120 (and/or upstream of the cooling arrangement 110, thegas-to-air exchanger 210, and/or the gas-to-air exchanger 310). In someexamples, the heater flue gas may be relatively cooler than the inputflue gas stream 10 and could thus potentially improve the efficiency ofthe cooling arrangement 110 by reducing the overall temperature of thecombined flue gas stream 10 (including the heater flue gas).

As noted above in the description of FIG. 1 , the driver 160 may includean internal combustion engine, a gas turbine, or any other type ofcombustion based driver configured to provide mechanical energy to drivethe compressor 150. As a product of this combustion process, the driver160 produces a driver flue gas. The driver flue gas is transported outof the driver 160 into the waste heat recovery unit 420 via the conduit124.

The power generator 430 may also include a combustion based powergenerator, such as a gas turbine or combustion engine, which generatespower (e.g., electricity) for powering one or more components (e.g.,gas-to-air exchangers 210, 310, blowers 212, 214, 312, etc.) of thecarbon capture system. As such, the power generator 430 produces agenerator flue gas, which is transported out of the power generator 430and into the waste heat recovery unit 420 via a conduit 402.

The waste heat recovery unit 420 is an energy recovery device (e.g.,heat exchanger) configured to transfer heat from the generator flue gasand/or the driver flue gas to the heat medium to further heat the heatmedium so as to supplement the heat from the fired heater 410 prior totransporting the heated heat medium to the regenerator 130. In someexamples, the regenerator 130 may return the spent heat medium (via aconduit 404) to the fired heater 410 and/or the waste heat recovery unit420 so as to re-heat the heat medium.

With this arrangement, the waste heat recovery unit 420 may enablereducing parasitic loads associated with heating the heat medium byharnessing waste heat from the driver flue gas and/or the generator fluegas to efficiently heat the heat medium for the solvent regeneration andCO2 stripping process (e.g., by reducing an overall amount of fuel thatwould otherwise be consumed to heat the heat medium without the wasteheat recovery unit 420).

After recovering heat from the generator flue gas and/or driver fluegas, the flue gas is transported out of the waste recovery unit 420(e.g., via conduit 408) for combination with the flue gas stream 10 at afront-end of the carbon capture system 400 (e.g., as shown in FIG. 4 )or at any other position upstream of the absorber 120. In some examples,the flue gas flowing out of the waste heat recovery unit 420 is coolerthan the input flue gas stream 10, and could thus facilitate improvingthe efficiency of the cooling arrangement 110 and/or the absorber 120 bycausing the combined flue gas stream 10 (including the flue gas from thewaste heat recovery unit 420) to have a lower overall temperature.

FIG. 5 is a schematic illustration of an example carbon capture system500 that includes another example heating arrangement, according to thepresent disclosure. System 500 depicts an example embodiment of system100 in which the heating arrangement 140 includes two waste heatrecovery units 420, 520, the fired heater 410, and the power generator430.

In particular, the system 500 includes a first waste heat recovery unit420 to receive (via conduit 124) the driver flue gas from the driver 160(similarly to system 400), and a second separate waste heat recoveryunit 520 to receive (via conduit 402) the generator flue gas 402 outputfrom the power generator 430. The second waste heat recovery unit 520extracts heat from the generator flue gas flowing into the waste heatrecovery unit 520 (via conduit 402) from the power generator 430 tofurther heat the heat medium flowing into the regenerator 130. Forexample, as shown, the heated heat medium flows out of the waste heatrecovery unit 520 via conduit 502 to be combined with the heated heatmedium output from the fired heater 410 and/or the waste recovery unit420 upstream of the regenerator 130.

Furthermore, in the illustrated example, the generator flue gas (afterbeing used in waste heat recovery unit 520 to heat the heat medium) istransported out of the waste heat recovery unit 520 (e.g., via conduit508) for combination with the input flue gas stream 10 at a front-end ofthe carbon capture process 500 (or at any other position upstream of theabsorber 120) in line with the discussion above for the spent flue gasexiting the waste heat recovery unit 420.

In some examples, the arrangement of carbon capture system 500 may beadvantageous for an industrial facility application in which the powergenerator 430 is not necessarily located near the compressor 150, thedriver 160, and/or the waste heat recovery unit 420.

Although not shown, in some examples, the heater flue gas output fromthe fired heater 410 may alternatively be routed to the waste heatrecovery unit 420, 520, and/or another waste heat recovery unit (notshown) to extract additional heat for further heating the heat mediumprior to combining the heater flue gas with the input flue gas stream10.

FIG. 6 is a schematic illustration of an example carbon capture system600 that includes yet another example heating arrangement, according tothe present disclosure. System 600 depicts an example embodiment of thesystem 100, in which a single driver 160 is used both for powergeneration and for driving the compressor 150. That is to say, a samedriver 160 in the configuration of system 600 may perform the functionsdescribed above for the power generator 430 of FIGS. 4-5 (e.g., generatepower for powering one or more components of the system 600), as well asto drive CO2 compression by the compressor 150. For example, the driver160 of system 600 may be implemented as an internal combustion engineand/or a gas turbine that both generates power for various components ofthe system 600 as well as generates mechanical energy for actuating thecompressor 150.

In line with the discussion above, the waste heat recovery unit 420 canreceive a driver flue gas from the driver 160 (via conduit 124) and mayuse heat from the driver flue gas to heat the heat medium flowing out ofthe waste heat recovery unit 420 and into the regenerator /stripper 130.

As used in this specification, including the claims, the term “and/or”is a conjunction that is either inclusive or exclusive. Accordingly, theterm “and/or” either signifies the presence of two or more things in agroup or signifies that one selection may be made from a group ofalternatives.

The many features and advantages of the present disclosure are apparentfrom the written description, and thus, the appended claims are intendedto cover all such features and advantages of the disclosure. Further,since numerous modifications and changes will readily occur to thoseskilled in the art, the present disclosure is not limited to the exactconstruction and operation as illustrated and described. Therefore, thedescribed embodiments should be taken as illustrative and notrestrictive, and the disclosure should not be limited to the detailsgiven herein but should be defined by the following claims and theirfull scope of equivalents, whether foreseeable or unforeseeable now orin the future.

What is claimed is:
 1. A system for processing a flue gas stream, thesystem comprising: a carbon dioxide (CO2) absorber configured to receivethe flue gas stream; a solvent regenerator in fluid communication withthe CO2 absorber, the solvent regenerator configured to receive a richsolvent from the CO2 absorber; a fired heater in fluid communicationwith the solvent regenerator, the fired heater configured to heat andtransport a heat medium toward the solvent regenerator, and the firedheater further configured to generate a fired heater flue gas andtransport the fired heater flue gas by means of a fan or a blower out ofthe fired heater for combination with the flue gas stream at a positionupstream of the CO2 absorber; and the solvent regenerator is configuredto generate a CO2 rich stream comprising CO2 from the flue gas streamand CO2 from the fired heater flue gas, and the CO2 rich stream isdehydrated, compressed and sent to underground geological storage forpermanent sequestration.
 2. The system of claim 1 further comprising adehydration unit configured to remove water from the CO2 rich stream. 3.The system of claim 2, wherein the system is configured to use the waterremoved from the CO2 rich stream by the dehydration unit within thesystem to reduce make-up water requirements.
 4. The system of claim 2,wherein the system is configured to use the water removed from the CO2rich stream by the dehydration unit within the host facility forindustrial use.
 5. The system of claim 2, wherein the system isconfigured to use the water removed from the CO2 rich stream by thedehydration unit as a revenue source.
 6. A system for processing a fluegas stream, the system comprising: a carbon dioxide (CO2) absorberconfigured to receive the flue gas stream; a solvent regenerator influid communication with the CO2 absorber, the solvent regeneratorconfigured to receive a rich solvent from the CO2 absorber; and a firedheater in fluid communication with the solvent regenerator, the firedheater configured to heat and transport a heat medium toward the solventregenerator, wherein the heat medium is the rich solvent and the firedheater further configured to generate a fired heater flue gas andtransport the fired heater flue gas out of the fired heater forcombination with the flue gas stream at a position upstream of the CO2absorber.